@Ahiru-san Include @Ahiru-san in your post and this person will be notified via email.

TOTAL PRODUCTIVE MAINTENANCE

1) My company is moving toward TPM. I like the system, but have never helped implement one before. Can you recommend a good book on where to start, how to use a planned, systematic approach, mistakes to avoid and so on? Otherwise, I will probably start by working my way through the 8 pillars left to right. (Pedantic? Who said I was pedantic?)

2) Also, is there any good reason NOT to start with Autonomous Maintenance (AM)? Upper management wants me to start with an overview to let people know what’s coming, then focus first on AM. I believe the idea is to get more employee involvement, and to keep the machines running better right away. Comments? Opinions?

@MikeC Include @MikeC in your post and this person will be notified via email.

Keep in mind there are two “TPMs” … the original Total Productive Maintenance and the modernized Total Productive Manufacturing. Total Productive Maintenance blurred the distinction between maintenance and production. In many organizations, there was limited impact beyond those two functions. As a result, most TPMaint implementations failed.

Total Productive Manufacturing recognizes the entire organization must be involved. JIPM (Japanese Institute of Plant Maintenance … the key sponsoring organization for TPMaint) has largely picked up on this and increased their focus, but it’s not universal.

Another consideration is the use of the term “autonomous maintenance.” Many organizations struggle with adoption from both operators and mechanics. From the operators, I hear words like “if you want me to do maintenance work, pay me like a mechanic.” On the other extreme, there are rumblings of “all you’re trying to do is replace the mechanics with the operators and pay them a lower wage.” There is also the inherent limitation of the words. We usually have to explain what is meant by autonomous … that’s simply an education issue and shouldn’t affect implementation. The limiting term however is using “maintenance.” On the surface, there is no focus on safety, quality, efficiencies, changeovers, timing, etc. Obviously, ideal monitoring checks would be preventive, predictive, and all encompassing. When we’re helping implement TPMfg, we simply refer to the monitoring initiative as Online Checks. Online Checks would then replace the Autonomous Maintenance pillar normally seen.

Bottom line: depending on your location and level of support, you may want to fine-tune the approach, even to the point of calling it Total Productive Manufacturing.

@Sivakumar-CS Include @Sivakumar-CS in your post and this person will be notified via email.

If your company is a general engineering industry refer

” TPM for Fabrication and assembly Industries ” by Kunio Shirose

If your company is a process industry refer

” TPM for Process Industries ” by Tokutaro Suzuki

Methodology to start or kick off TPM :

Select the worst maintained machine / area as a model where you can start implementing the basics as follows

5S Implementation , 1S, 2S and 3S ( Step by Step approach ) Conduct a three level audit ( Self, Section Chief and Management Audit ) Clear the minimum score of 90, 85 and 80 for the above three levels of audit and move to the next step of implementation.

Implement JH on the model machines – One step at a time , conduct three level audits and move to the next step…

Complete Step 3 in JH and start implementing FI pillar by collecting Loss information and take the facilitation from other pillars to improve the efficiency of the machines and processes.